Ultra-thin, single-ply battery separator

ABSTRACT

A battery separator is made from a microporous polyolefin membrane having a thickness of about 0.33 mills to about 0.5 mils.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 08/650,210 filed May 20, 1996,now U.S. Pat. No. 5,691,077, which is a continuation of U.S. application Ser. No. 08/359,772 filed Dec. 20, 1994, now abandoned.

FIELD OF THE INVENTION

The present invention is directed to an ultra-thin, single-ply battery separator.

BACKGROUND OF THE INVENTION

In batteries, the anode and cathode are separated from one another by a separator. Today, "lithium batteries" are very popular because they are able to generate high energy outputs. The lithium battery market can be divided into two groups, the "primary" lithium battery and the "secondary" lithium battery. The primary lithium battery is a disposable battery, while the secondary lithium battery is a rechargeable battery.

In batteries, thin battery separators can provide several advantages that can improve the battery's performance and design. First, thinner separators enable attainment of higher rate capabilities. This means that the battery is able to produce higher current densities across the membrane because the electrical resistance of the separator can be reduced by reducing the separator's thickness. For a correlation of Gurley value to electrical resistance: See generally, Callahan, R. W. et al, "Characterization of Microporous Membrane Separators," Mar. 1-4, 1993 delivered at the Tenth International Seminar on Primary and Secondary Battery Technology and Application sponsored by Florida Educational Seminars, Inc., 2836 Banyon Blvd. Circle N.W., Boca Raton, Fla. 33431. The higher rate capabilities are important where quick power is needed (e.g., for acceleration in an electrical vehicle). Second, thinner separators allow the use of thinner electrodes. This means that the battery attains better electrode utilization and electrode cycling. The electrode utilization means that smaller batteries with equivalent power can be produced. The better electrode cycling means a greater number of rechargings over the battery's life. Third, thinner separators allow greater choice in separator design. In other words, various thin separators can be combined to custom design a separator for a particular battery.

Accordingly, there is a need in the battery arts for thinner battery separators.

SUMMARY OF THE INVENTION

A battery separator is made from a microporous polyolefin membrane having a thickness of less than or equal to 0.5 mil.

DESCRIPTION OF THE INVENTION

The present invention shall be described in further detail below by way of the following detailed description and the non-limiting examples.

The battery separators according to the instant invention comprises an ultra-thin layer. The layer is, of course, microporous and is discrete. For example, see: Kesting, R. E., Synthetic Polymeric Membranes, 2nd Ed., John Wiley & Sons, New York City, N.Y., (1985) at section 8.2 versus Ibid., Chapter 7, this reference is incorporated herein by reference.

Polyolefin, as used herein, refers to a class or group name for thermoplastic polymers derived from simple olefins. Exemplary polyolefins include polyethylene and polypropylene. Polyethylene refers to, for example, polymers and copolymer substantially consisting of ethylene monomers. Polypropylene refers to, for example, polymers and copolymers substantially consisting of propylene monomers.

The thickness of these separators is less than or equal to 0.5 mil (about 12 microns). These separators preferably range in thickness between about 0.5 mil (about 12 microns) and about 0.3 mil (about 7 microns).

The process, by which the inventive separators are made, broadly comprises the following steps: extruding a polymer to form a sheet; annealing the sheet; and stretching the annealed sheet. The specific methods for making these sheets, particularly polyethylene or polypropylene, will be discussed with references to the method of making membranes having a thickness greater than 1 mil. By way of non-limiting example, the following references, each of which is incorporated herein by reference, illustrate the state of the art for making membranes having a thickness greater than 1 mil: U.S. Pat. Nos.: 3,426,754; 3,588,764; 3,679,538; 3,801,404; 3,801,692; 3,843,761; 3,853,601; 4,138,459; 4,539,256; 4,726,989; and 4,994,335, each of the foregoing is incorporated herein by reference. Knowledge of these methods being assumed, the inventive process for making thin membranes shall be described below by way of explaining the differences between the prior art methods for making standard films (thickness greater than 1 mil) and inventive method of making a thin film (thickness less than about 1/2 mil).

The differences discussed below regarding extrusion, annealing, and stretching are based upon a die configuration of a 27" die equipped with a 70 mil mandrel gap. If the die configuration changes, then the differences will change. For example, if a 6" die is used, the die temperature difference between standard film process and thin film process is much smaller. Regardless of die configuration, thin films require less quench air.

With regard to extrusion conditions, standard film processes typically require stronger quench air conditions and lower extrusion temperatures than thin film processes. For example, the relevant quench conditions for a standard film process include: an air pressure of about 6" H₂ O; an air ring gap in the range of 10/64 to 15/64 inches; and an air ring height of 1 to 2 inches; on the other hand, the relevant quench conditions of a thin film process include: an air pressure of about 0.6 to 3.0" H₂ O; an air ring gap in the range of 5/64 to 10/64 inches; and a ring height of about 1 to 2 inches. The relevant extrusion conditions for a standard film process (using Exxon's Escorene PP 4292 resin as an example) include: a die temperature in the range of 191 to 198° C. and a barrel temperature of 200 to 205° C.; on the other hand, the relevant extrusion conditions for a thin film process (using the same material) include: a die temperature in the range of 210° C. (for 0.5 mil final product) to 224° C. (for 0.33 mil final product) and a barrel temperature of 210° C.

With regard to annealing and stretching conditions, the inter-ply adhesion (measured as peel strength) must be lower than that of the standard process, so that the individual plies do not split (i.e. tear apart) when they are deplied. The ability to resist splitting is proportional to the ply's thickness. Thus, if the plies stick together (due to adhesion) and the stickiness is greater than the split resistance, then the plies cannot be separated (deplied) without splitting. For example, the adhesion of plies having a thickness of about 1 mil should be less than about 15 grams/inch, whereas for 0.5 mil plies, the adhesion should be less than about 8 grams/inch, and for 0.33 mil plies, less than about 5 grams/inch. To lower the adhesion values, the annealing/stretching temperatures for the inventive process are less than those for the standard process. For example, the annealing/stretching temperatures for a polypropylene film would be in the range of 120-125° C. (inventive process), compared to range of 140-150° C. (standard process), and for a polyethylene film about 110° C. (inventive process compared to about 115° C. (standard process).

Further information about the foregoing invention may be obtained from the following non-limiting examples. The test methods referred to herein are set forth below.

Test Methods

Gurley ASTM-D726(B)

Gurley is a resistance to air flow measured by the Gurley densometer (e.g. Model 4120). Gurley is the time in seconds required to pass 10 cc of air through one square inch of product under a pressure of 12.2 inches of water.

Thickness

Method: T411om-83 developed under the auspices of the Technical Association of the Pulp and Paper Industry. Thickness is determined using a precision micrometer with a 1/2 inch diameter, circular shoe contacting the sample at seven (7) PSI. Ten (10) individual micrometer readings taken across the width of the sample are averaged.

Porosity ASTM D-2873

Density ASTM D-792

Peel Strength

Peel strength is measured using a tension and compression tester to determine the force in grams required to separate two one-inch wide sections of bonded membrane. The peel rate is 6 inches/minute. Three measurements are taken across the web and averaged.

Melt Index ASTM D 1238; PE: 190° C./2.16 Kg; PP: 230° C./2.16 Kg.

EXAMPLE

Ultra-thin, single-ply battery separators, as disclosed above, were made in the following mnanner:

The polypropylene and polyethylene resins used are set forth in TABLES 1 & 2:

                  TABLE 1                                                          ______________________________________                                         Polypropylene (PP Monopolymer)                                                                 Density  Melt Index                                              Resin (g/Cm.sup.3) (g/10 min) Supplier                                       ______________________________________                                         A    Escorene   0.90     1.4      Exxon Chemical                                  PP4292                                                                        B Fina PP 327l 0.905 1.5 Fina Oil &                                                Chemical                                                                   C Fina PP 328l 0.905 1.1 Fina Oil &                                                Chemical                                                                   D Escorene 0.90 1.4 Exxon Chemical                                              PP4292                                                                         (nucleated)                                                                   E Escorene 0.90 1.4 Exxon Chemical                                              PP4372*                                                                       F Escorene 0.90 3.0 Exxon Chemical                                              PP3182                                                                      ______________________________________                                          *contains an antiblocking agent                                          

                  TABLE 2                                                          ______________________________________                                         Polyethylene (HDPE)                                                                             Density  Melt Index                                             Resin (g/cm.sup.3) (g/10 min) Supplier                                       ______________________________________                                         G    Fina        0.958    0.70     Fina Oil &                                     HDPEGF7750   Chemical                                                         H Escorene 0.964 0.30 Exxon Chemical                                            HDZ107                                                                      ______________________________________                                    

The extruder equipment was configured, as set forth in TABLE

                  TABLE 3                                                          ______________________________________                                         Extruder                                                                           L/D     Barrel  Die     Die    Land   Blow-up                                Ratio Size Size Opening Length Ratio                                         ______________________________________                                         E1  24      2.5"    12" or 27"                                                                             70 mil 3"     1                                      E2 24 3.5" 12" or 27" 70 mil 3" 1                                              E3 30 1.25"  6" 70 mil 3" 1                                                  ______________________________________                                    

                                      TABLE 4                                      __________________________________________________________________________     Extrusion Condition                                                                                           Quenching                                          Resin (See Extruder/Die Extruder Melt Die Air Ring Air Press Air Ring                                                     Line                                Tables 1 Size (See Temp Temp Temp Height (inches Opening Thickness                                                        Speed                              Product & 2) Table 3) (° C.) (° C.) (° C.) (inch)                                                     H.sub.2 O) (inches) (mil)                                                      (ft/min)                         __________________________________________________________________________     P1  A    E3/6" 200  205                                                                               205                                                                               1"   1.5" 0.078                                                                               0.38 42                                 P2 C E3/6" 205 215 215 1" 1.5" 0.078 0.38 42                                   P3 C E2/27" 230 243 243 1" 1.2" 0.078 0.38 47                                  P4 A E2/27" 210 224 224 1" 1.2" 0.078 0.38 50                                  P5 A E2/12" 220 224 224 1" 1.2" 0.078 0.38 50                                  P6 B E2/27" 210 224 224 1" 1.2" 0.078 0.38 50                                  E1 G E1/27" 200 220 200 1" 1.0" 0.078 0.38 60                                  E2 H E1/12" 180 199 185 1.25"   1.0" 0.094 0.59 60                           __________________________________________________________________________

The precursor films were annealed in an 8-ply film. This means that since the precursor films are extruded as inflated tubes, when they are collapsed, they created a 2-ply film. Four of these 2-ply films are wound up together to make the 8-ply film. The annealing conditions are set forth below in TABLE 5.

                  TABLE 5                                                          ______________________________________                                         Annealing Conditions                                                                                         Annealing                                                                             Peel Strength                               Product (see Table 4) Annealing Temp., ° C. Time, Min (gram/inch)     ______________________________________                                         P1          136           16       --                                            P2 140 16 --                                                                   P3 120 16 --                                                                   P4, P5 120 16 2                                                                P6 135 16 0                                                                    E1 110 19 1                                                                    E2 115 19 1                                                                  ______________________________________                                    

The annealed precursor films are stretched to form microporous membranes. The annealed precursor films were stretched as 16-ply films (8 rolls of 2 ply from an extruded tubular precursor). Alternatively, the annealed precursor films may be stretched as an 8-ply film or 24-ply film. The stretching conditions are set forth in TABLE 6:

                                      TABLE 6                                      __________________________________________________________________________     Stretching Conditions                                                          Product (see                                                                         Cold Stretch,                                                                        Cold                                                                               Hot Stretch Hot Relax   Thickness                                TABLE 5) Temp (° C.) Stretch* Temp (° C.) Hot Stretch*                                                      Temp (° C.) Hot                                                         Relax*,.sup.1 (mil) Gurley                                                     (sec)                             __________________________________________________________________________     P4, P5                                                                               ambient                                                                              25% 120° C.                                                                       115%  120° C.                                                                       40%   0.33 12                                  P6 ambient 25% 135° C. 115% 135° C. 40% 0.33 10                  E1 ambient 40% 110° C. 110% 110° C. 50% 0.33  8                  E2 ambient 45% 115° C. 105% 115° C. 40% 0.5 11                 __________________________________________________________________________      *The percentage of stretching/relaxing was based on the original length        before cold stretching                                                         .sup.1 The relax step indicates that the stretched film is allowed to          shrink back.                                                              

What is claimed:
 1. A battery separator comprising a microporous polyolefin membrane having a thickness of about 0.33 mils to about 0.5 mils.
 2. A battery comprising the separator of claim
 1. 